Construction of composite metal articles



May 2, 1950 o. HEDLUND CONSTRUCTION OF COMPOSITE METAL ARTICLES Filed April 22, 1944 INVENTOR. 050K? HEDLU/VD Patented May 2, 195

TENT

CQNSTR'UCTIQN F COMPUSITEMETAL ARTICLES Oscar i-Tedlund, Battle Creek, Mich, assignor to Baton ,Manniacturing Company,

Cleveland,

Ciaims. it

This invention relates to the construction of composite metal articles and more particularly ,to the fabrication of composite metallic poppet valves for internal combustion engines.

It is the usual practice due to the corrosive and/or erosive effect of the combined high temperatures and lead oxide .generated in the 001m bustion of high octane fuels to coat and overlay the valve seat and outer surface of the valve head with an alloy of the composition of 80% nickel and 20% chromium to thereby resist the destructive action of the combustive gases and prolong the lift of the valves.

Heretofore, this coating or overlaying of the valve head and/or seat has been applied by means of an electric or gas welding process with the result that it provedslow and consequently costly. Furthermore, in so applying this metal, it was almost impossible to obtain a coating or overlaying of uniform thickness; it being par- ,ticularly desirable to obtain an article having uniform thickness of nickel-chromium alloy Without surface porosity and with uniform cohesion between the-metals to be bonded together.

The stem of that portion of the valve head not directly contacted by the combustive gases is ordinarily made of a comparatively inexpensive metal having extreme high tensile strength characteristics at elevated temperatures; such an alloy comprises .40 to 50% carbon; .30 to 30% silicon; a maximum of 370% manganese; 13.00 to 15.00% each of chromium and nickel; .20 to 50% molybdenum; 1.75 to 3.00% tungsten;

a maximum of .0373 each of phosphorus and sulphur; and the balance of iron.

An object of the invention is to provide a method of making a composite metallic poppet valve in a less expensive and speedier method.

Another object of the invention is to provide a method .of producing a composite metallic article having a substantially uniform coating of heat corrosion and/or erosion resistant metal.

Another object of the invention is to provide a valve having a head and valve seat coated or overlayed with a coat of heat corrosion and/or erosion resistant metal, said metal being effectively bonded to the stem ofthe valve.

A further object of the invention is to provide a composite valvehaving a head, seat, and stem of dissimilar metals effectivelybonded together with uniformcohesion throughout their juncture.

A still further object of the invention is to provide a method of bonding dissimilar metals together comprising assembling the metals in juxtaposed relationship; inserting the metals in Y 2 a container in the presence of an inert gas; sealing the metals within the container; heating the assembly to a predetermined temperature and then forging the assembly so as to provide a bond between the metals.

And yet, another-object of the inventionis to provide a method of making a composite metallic valve comprising preforming a number of dissimilar metallic members; assembling the members in complementary relationship; inserting the members in a metallic container in the presence of an inert gas; sealinglthe container; heating the container and members to a suit able forging temperature; forging the container and members so as to provide a welding of the metals throughout their complementary surfaces; removingthe container from the members,

and then forgingthe members so as to produce a valve having, an exposed head of one metal, a valve seat of another metal, and stem of still another metal, all effectively bonded together.

Other objects and advantages of the invention will appear from the following description taken inCOnIIECtiOII with the drawings forming a part of the specification, and which:

Figure 1 is aside elevational view of a pair of cylindrical members adapted to be welded together;

Figure 2 is a longitudinal sectional view of the members in assembly within a sealed container;

Figure 3 is a longitudinal sectional View of the members after initial forging and removal of the containers;

Figure 4 is a longitudinal sectional view .of the members after the second forging operation;

Figure 5 is a longitudinal sectional View of the members after subsequent forging and piercing operations;

Figure 6 is a fragmentary longitudinal sectional viewof the completed article;

Figure 7 is a longitudinal elevational View of a modified form of the invention similar to Figure,2; and

Figure 8 is a fragmentary longitudinal view of the completed article forming the modification of the invention.

Referring to the drawings for more specific details of the invention, It represents a cylindrical body member adapted to be welded to a cylindrical disk member l2. The body member it is made of metal possessing high tensile characteristics at elevated temperatures, whereas disk 1 2 is composed of a heat corrosion and/or erosion resistant metal.

In the process of bonding members It and 12 together, the complementary surfaces of the members are initially ground and thoroughly cleaned so as to provide smooth mating surfaces free of dirt or other foreign matter. The meinbers are next assembled in juxtaposed relationship and inserted in a container is in the presence of an inert gas. A cover plate It is then placed upon the container and welded or otherwise suitably secured thereto so as to hermetically seal the members within the container. By so sealing the members in the container in the presence of an inert gas, oxidation of the surfaces to be bonded is materially reduced with the result that a more effective and uniform Weld is possible between the members. The contained assembly is then heated to a suitable predetermined temperature and initially forged so as to provide for a uniform bonding of the members Ill and 52 throughout their juncture. tainer and cover are next removed from the forged members in any suitable manner so as to provide an assembly as indicated in Figure 3.

After the completion of the initial forging operation the assembly is further forged and machined in accordance with the teachings of the patent to McBride, No. 1,984,751 to thus provide a finished bimetallic valve is as indicated by Figure 6.

In a modified form of the invention, lllll repre- 1;

sents a cylindrical body member having an enlarged head 12 and an annular recess portion IM adapted to have bonded thereto a disk liifi and a ring H38. Ihe cylindrical member is preferably made of metal possessing high tensile strength characteristics at elevated temperatures, and the disk and ring are made of heat corrosion and/or erosion resistant metal.

In the assembling of the members to be bonded together, the disk to; is placed upon the enlarged head I92 in juxtaposed relationship thereto; and the ring I68 is slipped over the body of the cylindrical member ltii and placed in complementary relationship to the underside of the head adjacent the recess IN.

The assembly is then inserted in a container Hil complementary in shape to the assembly and is sealed therein in the presence of an inert gas by a cover H2 welded or otherwise suitably secured to the container.

The assembly and container are then heated and forged in a manner similar to the preferred embodiment of the invention with the resultant production of an article or valve H l shown by Figure 8.

While this invention has been described in connection with certain specific embodiments, the principle involved is susceptible of numerous other applications that will readily occur to persons skilled in the art. The invention is, there- 'fore, limited only as indicated by the scope of the appended claims.

What I claim is:

l. The method of making a composite metallic poppet valve comprising preforming a cylindrical body member; preforming a disk member complementary to the head of the body member; preforming a ring havinga part complementary to a portion of the body member; assembling the members in complementary relationship with the disk and ring in annular axial abutting relationship to one another and arranged juxtaposed the head of the body member on opposite sides thereof; inserting the members in a thin Walled container in the presence of an inert gas; seal- The con- 5 4 ing the members within the container; heating the container and members to a predetermined forging temperature; forging the container and members as a unit so as to provide for welding of the members one to another; removing the container from the bonded assembly further forging the composite structure to desired valve form and machining the valve to completion.

2. The method of making a composite metallic poppet valve comprising preforming a cylindrical body member possessing high tensile strength characteristics; preforming a heat corrosion and/0r erosion resistant disk member complementary to the head of the body member; preforming a ring of physical and chemical properties similar to the disk member having a part complementary to a portion of the body member; assembling the members in complementar relationship with the disk and ring in annular axial abuttin relationship to one another and arranged juxtaposed the head of the body memher on opposite sides thereof; inserting the memhers in a thin walled container in the presence of an inert gas; sealing the members within the container; heating the container and members to a predetermined forging temperature; forging the container and members as a unit so as to provide for welding of the members one to another; removing the container from the bonded assembly further forging the composite structure to desired valve form and machining the valve to completion.

3. The method of making a composite metallic poppet valve comprising preforming a cylindrical body member possessing high tensile strength characteristics at elevated temperatures; preforming a disk member of 80-20 nickel-chromium complementary to the head of the body memher; preforming a ring of similar constituency as the disk member having a part complementary to a portion of the body member; assembling the members in complementary relationship with the disk and ring in annular axial abutting relationship to one another and arranged juxtaposed the head of the body member on opposite sides thereof; inserting the members in a thin walled container in the presence of an inert gas; sealing the members within the container; heating the container and members to a predetermined forging temperature; forging the container and members as a unit so as to provide for Welding of the members one to another; removing the container from the bonded assembly further forging the composite structure to desired valve form and machining the valve to completion.

4. The method of making a valve for internal combustion engines having a mushroom shaped h ad, a stern integral therewith and a coating of protective material welded upon the head and seat of the valve comprising; preforming a metallic disk member; preforming an annular metallic ring member; preforming a cylindrical cone-shaped metallic member; inserting the members in abutting position in a thin walled sheet metallic container in the presence of an inert gas with the ring in annular axial abutting relationship upon the disk with a portion of the cylindrical member disposed therebetween; hermetically sealing the container with the members enclosed with the inert gas; heating the container and contents to predetermined temperature; forging the container and contents to provide for the bonding of the members together across the abutting surfaces of the members whereby two of the members afford a protective coating for the other member; removing the container from the forged welded members; further forging the members so as to provide a valve having a mushroom shaped head composed of the three members, two members coating the head and a stem integral therewith composed of the member that is coated.

5. The method of making a valve for internal combustion engines having a mushroom shaped head, a stem integral therewith, a coating of protective metal welded upon the head, and a coating of another protective metal welded upon the seat of the valve comprising; preforming a metallic member adapted to provide the head protective coating for the valve; preforming a second metallic member adapted to provide the protective coating for the seat of the valve; preforming a third metallic member adapted to provide the mushroom shaped head and integral stem of the valve; inserting the members in proper abutting relationship with the first and second metallic members in end abutting relationship to one another and juxtaposed the mushroom-shaped head of the third metallic member on opposite sides thereof in a thin metallic container in the presence of an inert gas; hermetically sealing the container with the members enclosed with the inert gas; heating the container and contents to predetermined temperature; forging the container and contents to provide for the bonding of the members together across the abutting surfaces of the members whereby two of the members afford a protective coating upon the third member; removing the container from the forged welded members; further forging the members so as to provide a valve having a mushroom shaped head composed of the three members, one member coating the head, the second member coating the seat and the third member forming the base, head and integral stem of the valve.

6. A method of making a composite metallic article comprising preforming a cylindrical body member; preforming a disk member complementary to the head of the body member; preforming a ring having a part complementary to a portion of the body member; assembling the members in complementary relationship with a disk and ring in annular axial abutting relation to one another and arranged juxtaposed the head of the body member on opposite sides thereof; inserting the members in a thin Walled metallic container in the presence of an inert gas; hermetically sealing the members within the container; heating the container and members to a predetermined forging temperature; forging the container and m mbers as a unit so as to provide for the welding of the members one to another; and then removing the container from the welded assembly.

OSCAR HEDLUND.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 242,194 Fleitman May 31, 1881 340,223 LEpine Apr. 20, 1886 673,525 Martin May 7, 1901 726,026 Canda Apr. 21, 1903 1,355,234 Lachm'an Oct. 12, 1920 1,374,110 Pittevil Apr. 5, 1921 1,658,925 Jardine Feb. 14, 1928 1,948,793 Lewis Feb. 27, 1934 1,956,818 Acre May 1, 1934 2,002,641 McBride May 28, 1935 2,052,862 Armstrong Sept. 1, 1936 2,059,584 Johnson Nov. 3, 1936 2,123,416 Graham 1- July 12, 1938 2,178,527 Wellman Oct. 31, 1939 FOREIGN PATENTS Number Country Date 487,464 Great Britain June 21, 1938 

